Plug Connector Overmolding for Cable Sealing and Strain Relief
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Solution Overview
Problem
The production of preassembled cables with electrical plug connectors is time-consuming due to the need for special rubber or plastic grommets for sealing, which complicates the assembly process and strain relief between the cable and the plug connector.
Innovation Solution
A method involving a plug connector with a contact carrier and insert for connecting and securing the cable, where the contact carrier is inserted into the sleeve part for electrical insulation and the insert provides strain relief and sealing, followed by overmolding with injection-molding material to protect and secure the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special rubber or plastic grommets are used for sealing the plug connector housing, then sealing protection against environmental influences is improved, but the production process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the sealing function with the housing structure itself by creating an integrated sealing arrangement where the housing parts form the seal without requiring separate grommets. This merging of functions eliminates the need for additional sealing components and simplifies the assembly process.
Solution Approach 2:
The housing structure is designed to perform multiple functions simultaneously: providing structural support, enabling mechanical assembly, and creating the sealing barrier. This multi-functionality eliminates the need for specialized sealing components and integrates the sealing function into the existing housing design.
2Reliability
If special rubber or plastic grommets are used for sealing, then sealing protection is improved, but the assembly process becomes more complex
Solution Approach 1:
The sealing function is merged with the housing structure, eliminating separate grommet components. The housing parts themselves form the sealing barrier, reducing the number of components and simplifying the assembly process while maintaining effective sealing protection.
3Reliability
If strain relief is provided using separate collets or grommets, then strain relief between cable and contact is improved, but the production process becomes more time-consuming
Solution Approach 1:
The strain relief function is combined with the housing structure and sealing arrangement. The same integrated components that provide sealing also provide strain relief, eliminating the need for separate collet or grommet components and reducing production time.
Solution Approach 2:
The housing and sealing components are designed to perform multiple functions: sealing the housing, providing strain relief, and enabling cable fixation. This multi-functionality reduces the total number of components needed and simplifies the production process.
Data Source
AI summary
A method for producing a preassembled cable having at least one electrical plug connector includes: inserting a free end of a cable through a sleeve part of the plug connector, connecting a signal conductor at the free end of the cable to an electrical contact of a contact carrier of the plug connector, introducing the connected contact carrier into the sleeve part, located on the cable, of the plug connector, introducing an insert into the sleeve part of the plug connector for relieving strain on the cable and for sealing off the sleeve part of the plug connector at the cable end, and encapsulating by injection-moulding at least a portion of the sleeve part of the plug connector with injection-moulding material.